rotalign ultra is shaft handbook edition 1 doc 40 200-06-12 web en (1)
DESCRIPTION
asdaasdasdaasd asd asd asddddddddddddddddddddddddddddddddddddddddddddddddddddddddddddd as dasssssssssssssssssssssssssssssssssssssss asd saaaaaaaasdTRANSCRIPT
-
Foreword
1
A users handbook
Dear Customer,
Welcome to the world of intelligent shaft alignment using ROTALIGN Ultra iS Shaft,
another innovative product from PRFTECHNIK, the inventors of laser shaft alignment.
This handbook sets out to help the instrument user work through the instrument with
the required ease. It is the standard work for both the Advanced Shaft and Standard
Shaft versions, and meant to be a quick learning tool that hopefully should make
compelling reading.
PRFTECHNIK Alignment Systems GmbH
Freisinger Str. 34
85737 Ismaning
Germany
Tel +49.89.99616-0
Fax +49.89.99616-100
Email [email protected]
Edition June 2012
Part number DOC 40.200.en
Firmware version 3.00
sensALIGN and ROTALIGN are registered trademarks of PRFTECHNIK Dieter
Busch AG. PRFTECHNIK products are the subject of patents granted and pending
throughout the world. Contents subject to change without further notice, particularly
in the interest of further technical development. Reproduction, in any form whatsoever,
only upon express written consent of PRFTECHNIK Alignment Systems GmbH.
Copyright 2012 by PRFTECHNIK Alignment Systems GmbH
-
ROTALIGN Ultra iS Shaft handbook
2
Foreword
ROTALIGN Ultra iS is industrys rst intelligent alignment system. The system combines
the features of the tested and proven ROTALIGN Ultra iS computer together with
those of the next generation sensALIGN sensor and laser. ROTALIGN Ultra iS computer
features a 5.7-inch (145 mm) colour TFT sunlight readable full VGA screen, a fast
processor, an alphanumeric keyboard with strategically placed navigation keys that
handles all data entry functions, a long lasting rechargeable battery, handy on-screen
context menu, a remarkable le storage capacity and computer LEDs that give the
instant status of the alignment condition and laser beam adjustment.
sensALIGN sensor possesses an unlimited detector range making it possible to measure
grossly misaligned machines or those with long couplings. Both sensor and laser
incorporate Micro Electro Mechanical System (MEMs) allowing the measurement of
component rotational angle and vibration. sensALIGN sensor incorporates Bluetooth
for wireless transmission of measurement data to the system computer. Both sensor
and laser are powered using Lithium Polymer (Li-Po) rechargeable batteries.
In its completeness, the system handles the alignment of drive trains comprising up to
14 machines and includes intelligent features such as ellipse calculation, monitoring
environmental vibration, live measurement quality and suppression of coupling
backlash.
If you have any suggestions for improvement or corrections (not just to this manual,
but also for hardware), please drop us a line. We would be glad to make improve-
ments wherever possible.
We look forward to hearing from you.
PRFTECHNIK Alignment Systems
Ismaning, Germany
-
Contents
3
ContentsA users handbook ............................................................................................................... 1
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Chapter 1: ROTALIGN Ultra iS Shaft package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 ROTALIGN Ultra iS Shaft package ALI 40.000 .................................................................. 5
Chapter 2: System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 Safety notes ................................................................................................................. 11
2.2 Getting to know the ROTALIGN Ultra iS computer ....................................................... 13
2.3 sensALIGN laser ALI 4.910 ............................................................................................ 18
2.4 sensALIGN sensor ALI 4.900 ......................................................................................... 21
Chapter 3: Getting started with the ROTALIGN Ultra iS Shaft system . . . . . . . . . . . . 25
3.1 ROTALIGN Ultra iS Shaft system composition ................................................................ 25
3.2 Obtaining alignment readings in quick intelligent steps .................................................. 25
3.3 Tips and tricks .............................................................................................................. 29
Chapter 4: Shaft alignment application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.1 Starting the shaft alignment application ....................................................................... 33
4.2 Horizontal machine alignment - preparing for the alignment procedure ....................... 34
4.3 Check soft foot ............................................................................................................ 35
4.4 Mount the brackets ..................................................................................................... 35
4.5 Mount sensALIGN laser and sensor .............................................................................. 37
4.6 Switch ROTALIGN Ultra iS on and start application ....................................................... 38
4.7 Enter machine dimensions ............................................................................................ 39
4.8 Machine properties ..................................................................................................... 40
4.9 Coupling properties ..................................................................................................... 45
4.10 Laser beam adjustment .............................................................................................. 50
4.11 Taking measurements ................................................................................................. 52
4.11a Taking measurements using the sensALIGN sensor and laser cable ........................... 56
4.12 Results ...................................................................................................................... 57
4.13 Align machine ............................................................................................................ 62
4.14 Saving and printing measurement les ........................................................................ 69
4.15 Alignment completion ............................................................................................... 75
Chapter 5: Alignment features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5.1 Measurement modes .................................................................................................... 77
5.2 Measurement options .................................................................................................. 89
5.3 Measuring vibration .................................................................................................... 105
5.4 Set-up options ............................................................................................................ 109
5.5 Soft foot .................................................................................................................... 119
-
ROTALIGN Ultra iS Shaft handbook
4
Chapter 6: ROTALIGN Ultra iS Shaft configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 127
6.1 Conguration ............................................................................................................ 127
6.2 Creating templates ..................................................................................................... 140
6.3 Deleting created templates from the program manager .............................................. 142
6.4 Available applications and options ............................................................................. 144
6.5 Upgrading from Standard Shaft to Advanced Shaft version ......................................... 145
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Suggested shaft alignment tolerances ............................................................................... 147
ROTALIGN Ultra iS technical data ...................................................................................... 149
sensALIGN sensor and laser ON/OFF/CHARGE workow .................................................. 151
Declaration of conformity ................................................................................................. 152
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
-
Introducing ROTALIGN Ultra iS Shaft
5
Chapter 1: ROTALIGN Ultra iS Shaft package
ALI 40.000 is the standard ROTALIGN Ultra iS Shaft package.
For details of other available ROTALIGN Ultra iS stand-alone and add-on
packages, please contact your local PRFTECHNIK sales representative.
1.1 ROTALIGN Ultra iS Shaft package ALI 40.000
ALI 4.820 ROTALIGN Ultra iS Shaft case
ALI 4.202 ROTALIGN Ultra iS computer including:
ROTALIGN Ultra iS rechargeable battery
ALI 4.603
ROTALIGN Ultra iS stand ALI 4.201
ALI 4.910 sensALIGN laser [sensALIGN rechargeable
battery ALI 4.960 is mounted]
ALI 4.900 sensALIGN sensor [sensALIGN rechargeable
battery ALI 4.960 is mounted]
NoteFor details of other available ROTALIGN Ultra iS stand-alone and add-on
packages, please contact your local PRFTECHNIK sales representative.
ALI 4.820
ALI 4.202
ALI 4.910 ALI 4.900
Alignm
ent int
elligen
t Syste
m
-
ROTALIGN Ultra iS Shaft handbook
6
ALI 4.921-2 sensALIGN sensor and laser cable
ALI 4.651-I sensALIGN charger/adapter (universal)
for powering and charging sensALIGN
sensor/laser and rechargeable battery
ALI 12.502-2 PC/USB cable
ALI 12.503 USB/peripheral devices cable
ALI 12.651-I AC power supply/charger (universal) for
powering and charging ROTALIGN Ultra iS
computer and rechargeable battery
ALI 4.921-2 ALI 4.651-I ALI 12.503
ALI 12.502-2 ALI 12.651-I
-
Introducing ROTALIGN Ultra iS Shaft
7
ALI 2.113 SET Compact chain-type bracket set
includes: chains ALI 2.114, ALI 2.115,
support posts ALI 2.170, ALI 2.171,
ALI 2.172, ALI 2.173, ALI 2.174 and storage
pouch ALI 3.590-200
ALI 2.905 Lens cleaning cloth
ALI 3.588 Tape measure mm/inch
DOC 40.100.en ROTALIGN Ultra iS Shaft pocket guide
DOC 40.200.en ROTALIGN Ultra iS Shaft
operating instructions
DOC 4.900.de/en ROTALIGN Ultra product catalog
ALI 2.113 SET
ALI 2.905
ALI 3.588DOC 40.200.en
DOC 40.100.en
DOC 4.900.de/en
-
ROTALIGN Ultra iS Shaft handbook
8
ALI 13.700 CD ALIGNMENT CENTER CD
ALI 4.741 ROTALIGN Ultra Advanced Shaft
Firmware registration certificate
(not shown)
ALI 4.905 Vibration check probe
ALI 4.451 USB memory stick
0 0739 1055 Allen key (2.5 mm)
ALI 13.700 CD
ALI 4.451
0 0739 1055
ALI 4.905
-
Introducing ROTALIGN Ultra iS Shaft
9
1.1.1 Optional ROTALIGN Ultra iS components
ALI 4.605 ROTALIGN Ultra iS disposable battery
housing
ALI 4.615 Desktop charging station for ROTALIGN
Ultra iS rechargeable battery
ALI 4.410 Dust cap for computer sensor socket
ALI 4.615ALI 4.605
ALI 4.410
-
ROTALIGN Ultra iS Shaft handbook
10
This page intentionally left blank
-
Introducing ROTALIGN Ultra iS Shaft
11
Chapter 2: System description
2.1 Safety notes
ROTALIGN Ultra iS is to be used in industrial environments only for alignment of
turbine components, shafts, bores, measurement of straightness and atness of
different surfaces. It is dust proof and water resistant with a rating of IP 65. Although
shockproof, care must be taken to ensure that the instrument is not subjected to
mechanical knocks. ROTALIGN Ultra iS must be operated only by properly trained
personnel. No liability will be assumed when components or operating procedures as
described in this manual are altered without permission of the manufacturer.
2.1.1 Symbols used in this handbook
The following symbols are used in this manual in order to draw the readers attention
to especially important text, such as possible sources of danger or useful operating
tips.
This symbol denotes general information and tips regarding operation of
ROTALIGN Ultra iS.
This symbol denotes information which must be followed in order to avoid
damage to equipment.
This symbol denotes information which must be followed in order to avoid
personal injury.
Numbers in red circles indicate the corresponding operating step described in
these instructions and must be performed exactly.
2.1.2 CE compliance and electromagnetic compatibility
ROTALIGN Ultra iS fullls the EC Guidelines for electric devices and those relating to
electromagnetic compatibility as indicated in the conformity certicate attached in the
appendix. The certicate may also be downloaded from the PRFTECHNIK website.
2.1.3 Laser safety
The ROTALIGN Ultra iS system uses sensALIGN laser ALI 4.910. According to IEC
60825-1, sensALIGN laser is classied as a Class 2 laser product. The laser operates
at 635 nm and has a maximum radiant power
-
ROTALIGN Ultra iS Shaft handbook
12
Do not look directly into the laser beam at any time. (The natural blink
reaction of the human eye is normally sufcient to protect the eyes from
any dangers posed by looking at the laser beam briey. But as natural blink
reaction may fail to occur, care should be taken to avoid staring into the
beam.)
Do not insert any optical devices into the beam path.
The red LED on the front of sensALIGN laser illuminates whenever the laser
beam is emitted.
CAUTION Use of controls or adjustments or performance of procedures
other than those specied herein may result in hazardous radiation
exposure.
2.1.4 Component labelling
The laser safety labels are afxed on the housing of sensALIGN laser at the positions
shown in the diagram below. The rechargeable battery label is located on the rear of
sensALIGN rechargeable battery.
WARNING
Do not look directly into the laser beam at any time. (The natural blink
reaction of the human eye is normally sufcient to protect the eyes from
any dangers posed by looking at the laser beam briey. But as natural blink
reaction may fail to occur, care should be taken to avoid staring into the
beam.)
Do not insert any optical devices into the beam path.
The red LED on the front of sensALIGN laser illuminates whenever the laser
beam is emitted.
CAUTION Use of controls or adjustments or performance of procedures
other than those specied herein may result in hazardous radiation
exposure.
CAUTION
Rechargeable lithium polymer battery6Wh 3,7V 1,6Ah Trange = -10C/14F to 50C/120FCharge only with battery charger ALI 4.651-Ibetween 0C/32F to 40C/104FAufladen nur mit Ladegert ALI 4.651-I im Bereich 0C/32F to 40C/104F
Caution;2126-1'-1)4%6) ;2126(-5%55)0&/);2126&7rn24)9325)62,-+,6)03)4%674e;21265,246'-4cuit ;-5325)34operlyManufacturer:>!/-+10)16 :56)050&H50%1-1+)40%1ywww.pruftechnik.com
sensALIGN
LASER RADIATION
CLASS 2 LASER PRODUCTIEC 60825-1:2007
P < 1mW, pulse < 400' &
$!%!#! " "!! !!"
DO NOT STAREINTO BEAM
UN
LIMITED PRE
CISI
ON
sens
ALIGNTM Laser
S.No.
Date
Type
112
1110
9
87
6
54
3
2
14
OPEN
LASER RADIATIONDO NOT STARE INTO BEAM
P < 1mW, pulse < 400s &=635nmCLASS II LASER PRODUCTAVOID EXPOSURE - Laser radiation
is emitted from this aperture
C A U T I O N
The black label is on the back of
sensALIGN rechargeable battery
ALI 4.910 which is mounted on
both sensALIGN laser ALI 4.910
and sensALIGN sensor ALI 4.900.
This label is found on
the side of sensALIGN
laser ALI 4.910.
The service and calibration
label is attached at the
bottom of both sensALIGN
sensor and laser.
In the above example, the
next calibration due date is
mid-May 2014.
1 2 3 4 5 6 7 8
May 2014
ALI 4.910
This circular label is located
on the outside of the
sensALIGN laser aperture.
This label is found
on the side of
sensALIGN laser
ALI 4.910.
This label is located on the top of
both sensALIGN laser and sensor,
and indicates the direction of the
clamping levers open position.
This label is located on the bottom of sensALIGN
sensor next to the countersunk hole, and indicates
the position to place the vibration check probe
-
Introducing ROTALIGN Ultra iS Shaft
13
2.2 Getting to know the ROTALIGN Ultra iS computer
The ROTALIGN Ultra iS computer has been developed to effectively handle both
simple and complex shaft, bore and turbine diaphragm applications. The computer is
also used to carry out straightness and atness measurements. ROTALIGN Ultra iS has
a customer-oriented user interface. It uses easy-to-follow icons and comprehensive
on-screen menus and hint texts, that enable even rst-time users to operate the
computer without difculty.
ROTALIGN Ultra iS is built to rugged industrial standards of shock and water resistance.
It contains a complete computer with a 5.7 inch (145 mm) color TFT full VGA display,
oval-shaped function and data entry keys, 4-way navigation keys, an On/Off/Enter
key, an up key, a clear key and a menu key.
USB port/Charger socketCharger socket
Sensor socket
Up/Clear/ Menu keys
Bluetooth communication LED
Function keys
Battery status LED
Data entry keys
Laser adjustment and alignment condition LEDs
Navigation keys
On/Off/Enter key
-
ROTALIGN Ultra iS Shaft handbook
14
2.2.1 Operating keys
The navigation keys are used to navigate through the menu and display items.
The Enter key in the centre is used to access any selected item or conrm an
action.
The On/Off/Enter key is used to perform the dual function of switching on
ROTALIGN Ultra iS, and accessing any selected item. To switch on, press and hold
e, the On/Off/Enter key briey.
The Up key is used as a back/return key, taking user to previously selected
function, or to exit current screen.
The CLR (Clear) key is used to delete information entered inadvertently.
The Menu key is used to call-up menu options related to the selected display
screen. Pressing it twice brings up the global menu.
The data entry keys are used to enter relevant data.
ROTALIGN Ultra iS possesses 3 function keys.
The Dimension key is used to access machine set-up where machine
dimensions and properties are dened.
The Measurement key is used to access the measurement screen.
The Result key is used to call alignment results into the display.
The label opposite is on the back of ROTALIGN Ultra iS
computer, afxed to the rechargeable battery in current use.
The above label is afxed on the back of ROTALIGN Ultra iS
computer ALI 4.202.
-
Introducing ROTALIGN Ultra iS Shaft
15
2.2.2 Computer LEDs
The battery status LED blinks green during the battery recharging process,
staying steady green when battery is fully charged.
The Bluetooth communication LED blinks blue while searching the neighbour-
hood for Bluetooth devices, staying steady blue when connected to the
sensALIGN sensor.
The four alignment condition LEDs are used to indicate the position of the laser
beam on the detector during beam adjustment, and the actual alignment status
after measurement.
LED Laser beam adjustment Alignment status
Blue Laser beam centred Excellent
Green Laser beam OK Acceptable
Amber Laser beam out of recommended
measurement part of detector
Bad
Red Laser beam off Grossly misaligned
-
ROTALIGN Ultra iS Shaft handbook
16
2.2.3 Power supply
ROTALIGN Ultra iS is powered using a 7.2 V 6.0 Ah Lithium-ion rechargeable battery
ALI 4.603, which is to be charged only using the battery charger ALI 12.651-I. This
can be done with the battery inside the computer. The computer may continue to be
used if the battery is charged inside it.
Alternatively, use 6 standard C size [IEC LR 14] batteries contained in the optional
battery compartment ALI 4.605.
If the ROTALIGN Ultra iS computer is not in use for extended periods of time,
a month or more, the rechargeable battery or the standard batteries should be
removed from the unit.
2.2.4 Replacing batteries
The rechargeable battery ALI 4.603 and the battery housing ALI 4.605 have identical
shapes and are therefore replaceable. If batteries require removal, turn over the
computer taking care not to damage the display and the hard keys. Undo the two
screws by turning them counterclockwise a quarter of a turn. With the screws
loosened, lift and pull the rechargeable battery or the battery housing (depending on
power supply source) out. The reverse procedure is used to mount back the recharge-
able battery or the battery housing back into the computer.
CAUTION
If the ROTALIGN Ultra iS computer is not in use for extended periods of time,
a month or more, the rechargeable battery or the standard batteries should be
removed from the unit.
-
Introducing ROTALIGN Ultra iS Shaft
17
Sensor socket
Ensure correct sensALIGN
sensor cable plug
orientation to avoid
damaging pins
USB host/slave port
The red dot on the USB
cable plug must match the
red dot on the USB port
Charger socket
The red dot on the charger
plug must match the red
dot on the battery socket
Connecting the battery
charger to ROTALIGN Ultra
iS computer The LED next
to the battery symbol on
the keypad blinks while
charging takes place.
Battery housing
ALI 4.605
If you are using the
standard C size batteries,
it is recommended to
replace all of them at once.
Note the battery polarity
when inserting them in the
battery housing ALI 4.605.
The housing is removed
and replaced in the same
manner as the rechargeable
battery ALI 4.603
6 C size [IEC LR 14]
batteries
Lift battery housing or
rechargeable battery after
undoing the screws
Replace battery housing
or rechargeable battery by
sliding it into the groove
appropriately
1 32
1
2
3
Note that available cables
may be connected to the
corresponding numbered
sockets as follows:
ALI 4.921-2
(sensALIGN sensor and
laser cable)
ALI 12.503 (short
USB cable), ALI 12.651-I
(charger)
ALI 12.502 (long USB
cable), ALI 12.503( short
USB cable), ALI 12.651-I
(charger)
ROTALIGN Ultra iS top panel connectors
-
ROTALIGN Ultra iS Shaft handbook
18
2.3 sensALIGN laser ALI 4.910
The semiconductor laser diode emits a ray of red light (wavelength 635 nm) which
is visible where it strikes a surface. The Class 2 laser beam is emitted with a diameter
of approx. 5 mm (3/16).
sensALIGN laser is turned on by pressing and holding the on/off switch briey. The
beam active LED lights red.
With sensALIGN laser on, DO NOT stare into the laser beam!
The beam is adjusted during set-up by changing its vertical and horizontal angles
using the position thumbwheels, so that the beam strikes the sensALIGN sensor lens
perpendicular to the lens surface.
sensALIGN laser is water and dust resistant (IP 65). The internal optics and electronics
are internally sealed, preventing possible contamination.
Information regarding the battery status, the rotational angle, the temperature and
the serial number of the sensALIGN laser are transmitted through the laser beam into
sensALIGN sensor. This information is further relayed to ROTALIGN Ultra iS computer.
WARNING
With sensALIGN laser on, DO NOT stare into the laser beam!
On/Off push button switch
Beam active LED
Horizontal beam position thumbwheel
Charger/adapter socket (shown covered)
Sliding dust cap
Clamping lever (depicted here in the open position)
Vertical beam position thumbwheel
Laser aperture
Battery status LED
-
Introducing ROTALIGN Ultra iS Shaft
19
sensALIGN laser ALI 4.910 is powered using sensALIGN rechargeable battery
ALI 4.960 a 3.7 V 1.6 Ah Lithium Polymer rechargeable battery. The rechargeable
battery is attached to the laser and is to be charged only using the sensALIGN charger/
adapter ALI 4.651-I, and is possible only when the battery is attached to the laser.
2.3.1 sensALIGN rechargeable battery ALI 4.960
Both sensALIGN laser ALI 4.910 and sensALIGN sensor ALI 4.900 are powered using
the sensALIGN rechargeable battery ALI 4.960. The battery is charged via the charger/
adapter socket using the sensALIGN charger/adapter ALI 4.651-I. If the battery capacity
is greater than 50% [acceptable capacity for measurement], the battery status LED on
both sensALIGN laser and sensor lights up green for 2 seconds on switching on.
During the charging process, the battery status LED blinks green. When the battery is
fully charged, the LED lights steady green if the charger remains connected.
Activity sensALIGN laser
battery status LED
sensALIGN sensor
battery status LED
sensALIGN laser
beam active LED
Switch on Lights up green for 3 seconds when battery run time is > 10 hrs
Blinks green every 3 seconds when battery run time is between 5 10 hrs
Blinks red every 3 seconds when battery run time is between 1 5 hrs
Blinks red constantly when battery run time is < 1 hr
Lights up green for 3 seconds when battery run time is > 10 hrs
Blinks green every 3 seconds when battery run time is between 1 5 hrs
Blinks red every 3 seconds when battery run time is insufcient for longer measurements
Blinks red constantly when battery run time is < 1 hr
Lights steady red when in beam nder mode
Blinks red when in measurement mode
Note that measuring can take place with both modes
Charging battery Blinks green when charging
Lights steady green when fully charged
Lights red when a failure occurs during charging
Blinks green when charging
Lights steady green when fully charged
Lights red when a failure occurs during charging
LED off
-
ROTALIGN Ultra iS Shaft handbook
20
To replace the rechargeable batteries, use the provided 2.5 mm allen key [0 0739
1055] to undo the two hex screws that afx the battery to either sensALIGN laser or
sensor.
Used batteries should be disposed of in an environmentally-sound manner! Used batteries should be disposed of in an environmentally-sound manner!
The position and removal
of sensALIGN rechargeable
battery ALI 4.960 is identical
in both sensALIGN laser
ALI 4.910 and sensALIGN
sensor ALI 4.900.
sensALIGN rechargable battery ALI 4.960
Hex screw
-
Introducing ROTALIGN Ultra iS Shaft
21
2.4 sensALIGN sensor ALI 4.900
sensALIGN sensor contains two position detectors, which measure the exact position
and inclination of the laser beam as the shafts are rotated. Integrated in the sensor
is Bluetooth technology for wireless transmission of measurement data to ROTALIGN
Ultra iS computer. sensALIGN sensor also transmits sensALIGN laser data to the
computer. The intelligent sensALIGN sensor technology is used to determine shaft
rotational angle and machine vibration.
Positioned at the front of sensALIGN sensor are following indicator LEDs:
Battery status LED
Bluetooth communication LED
Four beam adjustment LEDs
If for some reason (say space), the rechargeable battery is dismounted,
measurement may still take place by powering sensALIGN sensor using ROTALIGN
Ultra iS computer. In this case, connect the supplied sensALIGN sensor cable ALI
4.921-2 to the charger/adpter/sensor cable socket.
If for some reason (say space), the rechargeable battery is dismounted,
measurement may still take place by powering sensALIGN sensor using ROTALIGN
Ultra iS computer. In this case, connect the supplied sensALIGN sensor cable ALI
4.921-2 to the charger/adpter/sensor cable socket.
Note
On/Off push button switch
Charger/adapter/sensor cable socket(shown covered)
Clamping lever (depicted here in the locked position)
Battery status LEDClamping lever stopper (positioned on sensALIGN rechargeable battery)
Bluetooth communication LED
Laser beam adjustment LED (four in number)
Sliding dust cap
-
ROTALIGN Ultra iS Shaft handbook
22
2.4.1 Understanding the beam adjustment LEDs
The four beam adjustment LEDs provide additional help when adjusting the laser
beam position on sensALIGN sensor position detectors. The LEDs indicate the angle
and position at which the laser beam enters the sensALIGN sensor lens. The LEDs
blink either red or green depending on the angle at which the laser beam strikes the
sensALIGN sensor lens. Green indicates a small angle while red indicates a large angle
that must be corrected before beginning measurement.
Activity Laser beam adjustment LEDs
Switch on sensALIGN sensor All four LEDs light up red then continue to blink every two seconds
Laser beam striking dust cap [laser off]
All four LEDs blink red every second
Laser beam entering lens with a large angular deviation
One or more LEDs blinks red every second
Laser beam entering lens with little or negligible angular deviation but with an offset
All four LEDs blink green twice every second
Laser beam entering lens with neither appreciable angular deviation nor offset
All four LEDs blink green every second
2.4.2 Adjusting the laser beam
1. With the lens covered, let the laser beam strike the centre of the sensALIGN
sensor dust cap.
2. Slide the dust cap to open the lens. Observe the four laser beam adjustment
LEDs while adjusting the laser beam using the vertical and horizontal beam
positioning thumbwheels. The thumbwheels are used to adjust both the
horizontal and vertical laser beam angles.
3. Carry out this adjustment until all four LEDs are blinking green once every second.
4. If the LEDs are blinking green twice every second, the angle at which the laser
beam enters the lens is correct, but an offset is present. Eliminate the offset by
sliding back the sensALIGN sensor dust cap to cover the lens, then loosen the
chain type bracket supporting sensALIGN sensor and move the sensor sideways.
At the same time, release the sensALIGN sensor clamping levers and move the
sensor upwards and downwards until the laser beam is centred on the dust cap.
During this adjustment, DO NOT touch sensALIGN laser.
5. Open the lens by sliding the dust cap and check the blinking of the four LEDS.
If all four are blinking green once every second, then the laser beam has been
correctly centred.
All four LEDs blink red every
second when the laser
beam enters the lens with a
large angular deviation and
offset.
When one or more LEDs
blinks red every second, the
laser beam is entering the
lens with a large angular
deviation that must be
corrected.
When all four LEDs are
blinking green twice every
second, the laser beam is
entering the lens without
an appreciable angular
deviation. In this case,
only the offset needs to be
corrected.
-
Introducing ROTALIGN Ultra iS Shaft
23
2.4.3 Service and care of both sensALIGN laser and sensor
The calibration accuracy of sensALIGN sensor ALI 4.900 should be checked
every two years as indicated by the service and calibration label (shown at right)
afxed at the bottom of the sensor housing. sensALIGN laser does not require
calibration but should also be checked every two years. Refer to the service and
calibration label afxed at the bottom of the laser housing.
Please return the system components to your authorized PRFTECHNIK service
centre for calibration checking by the date indicated.
Any waste electrical and electronic parts of the ROTALIGN Ultra iS system
including memory sticks must be disposed of in accordance with the WEEE
(Waste Electrical and Electronic Equipment) Directive. Such parts must be taken
to the nearest collection facility.
If you have any questions regarding the WEEE Directive, please contact your local
PRFTECHNIK sales representative.
NoteThe calibration accuracy of sensALIGN sensor ALI 4.900 should be checked
every two years as indicated by the service and calibration label (shown at right)
afxed at the bottom of the sensor housing. sensALIGN laser does not require
calibration but should also be checked every two years. Refer to the service and
calibration label afxed at the bottom of the laser housing.
Please return the system components to your authorized PRFTECHNIK service
centre for calibration checking by the date indicated.
S.No.
Date
Type
112
1110
9
87
6
54
3
2
14
Any waste electrical and electronic parts of the ROTALIGN Ultra iS system
including memory sticks must be disposed of in accordance with the WEEE
(Waste Electrical and Electronic Equipment) Directive. Such parts must be taken
to the nearest collection facility.
If you have any questions regarding the WEEE Directive, please contact your local
PRFTECHNIK sales representative. Month indicated by small arrow next to the wheel
Year
-
ROTALIGN Ultra iS Shaft handbook
24
Page intentionally left blank
-
Getting started
25
Chapter 3: Getting started with the
ROTALIGN Ultra iS Shaft system
The ROTALIGN Ultra iS Shaft system is used for any shaft alignment application,
regardless of complexity. This intelligent System [iS] detects and displays any operator
error, eliminates the effects of unwanted external inuences such as machine
vibration, while producing precise and repeatable measurements.
3.1 ROTALIGN Ultra iS Shaft system composition
The system comprises:
The proven ROTALIGN Ultra iS computer which is the core of the ROTALIGN Ultra
measurement platform.
The intelligent sensALIGN sensor that uses intelliSWEEP a high denition
measurement mode that actively assists the user by automatically detecting
and eliminating error inuences such as coupling backlash, rotational angle and
vibration.
The intelligent sensALIGN laser that relays the rotational angle in which the
component is located as well as its battery status.
Other shaft alignment components such as brackets and other accessories
3.2 Obtaining alignment readings in quick intelligent steps 3.2.1 Mount components on machine train to be measured
Both sensALIGN sensor and laser are mounted on the shafts of the machine train to
be measured using the supplied compact chain-type brackets. The sensor and laser
are xed to the support posts by locking the yellow clamping levers. [Refer to section
4.5 for details on mounting components.]
3.2.2 Switch on both sensALIGN sensor and laser
Both sensALIGN sensor and laser are switched on by pressing their respective On/Off
push button switches.
3.2.3 Centre laser beam
The laser beam is centred on the sensor detector planes using the yellow position
thumbwheels and moving sensALIGN sensor vertically along the support posts or
horizontally by loosening the chain-type bracket. [Refer to Laser beam adjustment
in section 4.10.]
In addition to the shaft
alignment application,
the ROTALIGN Ultra
measurement platform also
includes bore alignment,
atness and straightness
measurement, hydro power
application and other
geometric applications.
-
ROTALIGN Ultra iS Shaft handbook
26
3.2.4 Press e to switch on the ROTALIGN Ultra iS computer Press and hold e the On/Off/Enter key briey. The opening screen below appears.
3.2.5 Enter machine dimensions
The machine set-up screen is accessed by pressing d. [Refer to section 4.7 for details on how to enter machine dimensions.]
3.2.6 Start measurement
Access the measurement screen by pressing m. Ensure laser beam dot is centred on the square target then rotate shafts. [Refer to section 4.11 for details on taking
measurements.]
The navigation keys are
used to access available
applications and options.
The navigation direction is
either upwards/downwards
or sideways.
-
Getting started
27
3.2.7 View alignment results
After measurement, press RES to view the alignment results.
3.2.8 Context menu items
A useful feature available in ROTALIGN Ultra iS computer is the availability of display
screen related context menu items for each individual screen. Useful menu items that
include accessing the program manager, turning the computer off and conguring
the instrument can be accessed via the context menu that appears when q is pressed at any time. The item Menu is used to access the global menu.
Context menu items
available from the program
manager screen
-
ROTALIGN Ultra iS Shaft handbook
28
3.2.9 Global menu
The ROTALIGN Ultra iS computer uses a global menu concept to shorten the distance
to reach any required menu item. The global menu appears in the following two
forms.
a configuration global menu that appears within the program manager
a complete global menu covering all menu items this appears within the
Shaft application
The global menu may be accessed at any time by pressing q twice.
Context menu items
available from the
measurement screen
Global menu when accessed
within the Shaft application
-
Getting started
29
3.3 Tips and tricks
3.3.1 Program manager
While in the program manager, the data entry keys are used to select the
corresponding application icon in a numerically ascending order. This is possible
only up to the tenth icon.
3.3.2 General
Pressing q twice opens the global menu. Pressing q long enough also opens the global menu. Pressing e for approximately 3 seconds prompts the turn off system dialog. Pressing e for approximately 7 seconds resets the system. For machine trains with more than one coupling position, pressing either h or i long enough moves the view of the train to the left or right respectively.
Pressing the corresponding data entry key moves the view to the respective
coupling position (observe inset in display).
The conguration global
menu accessed from the
program manager screen
The displayed view shows
machines A and B with
coupling 1
-
ROTALIGN Ultra iS Shaft handbook
30
Pressing either o or p moves the view of the train to the right or left respectively.
Pressing f or g zooms out or zooms in the machine image respectively. Note that any one of the train elements has to be highlighted for the zoom
function to respond.
The displayed view shows
machines B and C with
coupling 2. The view is
prompted from the previous
screen by pressing either
2 or p or i long enough.
-
Getting started
31
3.3.3 Dimensions (set-up)
When in set-up and units are set to Imperial system, entering a dimension as
11.3.8 corresponds to 11 3/8 in.
Pressing c while in set-up prompts the deletion of the selected machine. When selecting type of machine the orientation of the machine can be altered
by pressing either h or i. Pressing d twice while in set-up zooms the machine train out and in again. When entering le or element names, pressing o cycles through the characters
that can be entered. The characters are capital letters (upper case), small letters
(lower case) and numerals. With numerals selected, pressing 1 long enough enters the value P.
3.3.4 Measurement
Pressing m twice activates auto measurement.
In auto measurement any of the three measurement modes Continuous Sweep,
Multipoint or Static measurement is started directly by the appropriate action.
Sweep mode is activated by rotating the shafts
Multipoint is started by pressing e Static measurement is started by pressing either the data entry keys or any
of the navigation keys
3.3.5 Results
Pressing g and holding on, while in results, cycles the results between vertical (V), horizontal (H) and both H&V.
In auto measurement any of the three measurement modes Continuous Sweep,
Multipoint or Static measurement is started directly by the appropriate action.
Sweep mode is activated by rotating the shafts
Multipoint is started by pressing e Static measurement is started by pressing either the data entry keys or any
of the navigation keys
Note
-
ROTALIGN Ultra iS Shaft handbook
32
Page intentionally left blank
-
33
Chapter 4: Shaft alignment application
4.1 Starting the shaft alignment application
Before the application can be started, a licence code must be entered in the
licence manager. In most cases the application is licenced at the factory and
the system is delivered with the Advanced Shaft rmware registration certicate
ALI 4.741 which contains the entered licence code.
4.1.1 Starting the licence manager
After switching ROTALIGN Ultra on, use the navigation keys to highlight Conguration
icon.
Press e to access this option, then use the navigation keys to highlight the Licence Manager icon.
NoteBefore the application can be started, a licence code must be entered in the
licence manager. In most cases the application is licenced at the factory and
the system is delivered with the Advanced Shaft rmware registration certicate
ALI 4.741 which contains the entered licence code.
-
ROTALIGN Ultra iS Shaft handbook
34
With the icon highlighted, press e to access the Licence Manager screen. Use f/g to highlight Shaft Alignment, then press e to proceed with entering the application licence code (registration key) in the editing box.
After successful registration, a green check mark appears next to the application, and
the application level appears as a sufx to the rmware version.
The application shaft alignment can now be started.
Please refer to section 6.5 for a brief description on upgrading from the Standard
Shaft application level to the Advanced Shaft level.
4.2 Horizontal machine alignment - preparing for the
alignment procedure
Before using the Shaft Alignment application, prepare the machines as described
below.
Switch off the machines before commencing work, and make sure that they
cannot be started accidentally!
4.2.1 Solid, flat foundation
A solid, rigid foundation is required to obtain correct, lasting shaft alignment that
allows long-term uninterrupted machine service.
4.2.2 Machine mobility
If the machine to be moved stands directly on the foundations, it cannot be lowered
for alignment correction. It is therefore advisable to start with about 2 mm (80 mils)
of shims beneath the feet of both machines. Hydraulic or screw-type positioning aids
are recommended for horizontal movement.
The three application levels
available are Standard,
Advanced and Expert The
registered level will appear
as a sufx to the rmware
version.
WARNING
Switch off the machines before commencing work, and make sure that they
cannot be started accidentally!
-
35
4.2.3 Rigid couplings
Rigid couplings must be loosened before measurement so that they do not distort the
alignment condition.
4.2.4 Shaft play and coupling backlash
Axial shaft play is detected and compensated for in alignment results (but affects
machine operation).
4.2.5 Soft foot
Soft foot causes the machine frame distortion every time the bolts are loosened or
tightened, making proper alignment difcult or impossible.
4.2.6 Thermal growth, alignment targets, tolerances
These values can be obtained from the individual machine specications, and then
entered into the program. In addition, a built in thermal growth calculator can help
you derive these values from the observed changes in temperature.
4.2.7 Measurement separation
As the system requires no mechanical connections (such as cantilevered dial indicator
brackets) to span over the coupling during measurement, alignment may easily be
performed over large laser sensor separations.
Note that over very large distances the shafts and coupling may sag, and the machines
may need to be aligned to take this into account. Refer to the machine manufacturers
specications.
4.3 Check soft foot Refer to section 5.5 for soft foot.
4.4 Mount the brackets Mount the brackets on either side of the coupling on either the shafts or on the solid
coupling hubs, and both at the same rotational position.
Please note the following in order to obtain the highest possible measurement
accuracy and to avoid damage to equipment:
Ensure that the brackets t solidly onto their mounting surfaces!
Do not use self-constructed mounting brackets, or modify the original
bracket conguration supplied by PRFTECHNIK Alignment (for example,
do not use support posts longer than those supplied with the bracket).
CAUTION
Ensure that the brackets t solidly onto their mounting surfaces!
Do not use self-constructed mounting brackets, or modify the original
bracket conguration supplied by PRFTECHNIK Alignment (for example,
do not use support posts longer than those supplied with the bracket).
Horizontal shaft alignment
-
ROTALIGN Ultra iS Shaft handbook
36
4.4.1 Bracket mounting procedure
To t the compact chain brackets, refer to the diagram shown below and follow the
instructions carefully.
1. Choose the shortest support posts which will still allow the laser beam to pass
over or through the coupling. Insert the support posts into the bracket.
2. Fasten them in place by tightening the hex screws on the sides of the bracket
frame.
3. Place the bracket on the shaft or coupling, wrap the chain around the shaft
and feed it through the other side of the bracket: if the shaft is smaller than the
width of the bracket frame, insert the chain from the inside of the bracket as
shown in the diagram; if the shaft is larger than the bracket width, insert the
chain into the frame from the outside.
4. Catch the chain loosely on the anchor peg.
5. Turn the bracket thumbscrew to tighten the assembly onto the shaft.
6. Clip the loose end of the chain back onto itself.
The bracket should now be tight upon the shaft. Do not push or pull on the bracket
to check, since this could loosen its mounting.
To remove the brackets, loosen the thumbscrew, then remove the chain from its
anchor peg.
The compact chain-type brackets cover most situations, but in cramped or
special cases, other types of brackets may be required. Ask your PRFTECHNIK
representative for details. NoteThe compact chain-type brackets cover most situations, but in cramped or
special cases, other types of brackets may be required. Ask your PRFTECHNIK
representative for details.
1
2
3 4
5
6
Anchor peg
-
37
4.5 Mount sensALIGN laser and sensor
Mount sensALIGN aser on the support posts of the bracket xed on the shaft of the
left machine (usually reference machine), and sensALIGN sensor on the support posts
of the bracket xed on the shaft of the right machine (usually moveable machine)
as viewed from normal working position. Before mounting both sensALIGN laser
and sensor, make sure that the sure that the yellow clamping levers are in the open
position by placing them to the front. This enables components to slide onto the
support posts.
Fix both sensALIGN laser and sensor onto the respective support posts by locking the
yellow clamping levers. Lock the levers by pushing them backwards until they rest on
the stoppers. Ensure that the laser can pass over or through the coupling and is not
blocked.
Both sensALIGN laser and sensor should be at the same height, as low as possible, yet
just high enough for the beam to clear the coupling ange. They should also visually
appear to be rotationally aligned to each other.
Make the nal adjustments, loosening the brackets slightly if necessary, then rotating
them and retightening.
Clamping levers in the
open position
Clamping levers in the
open position allows
sensALIGN laser or sensor
to slide onto the support
posts.
Locking the clamping
levers by pushing them
against the stoppers xes
sensALIGN laser or sensor
onto the support posts.
Horizontal shaft alignment
Clamping lever in the
lock position
Laser
Sensor
Mount just high enough
to clear coupling
-
ROTALIGN Ultra iS Shaft handbook
38
4.6 Switch ROTALIGN Ultra iS on and start application
Press e and hold for a few seconds. The four laser adjustment and alignment condition LEDs light up. Shortly afterwards, the splash screen appears, followed by
the program manager screen below.
Use the navigation keys to highlight Shaft Alignment. Press e to access the application. The opening template in the set-up screen below appears.
The above screen will appear only if the customization option Resume policy
has been set to Resume les manually. (See customization - described in section
6.1.9)
If desired, elements in
the machine train can be
displayed in 2-D format
using the dimensions
screen context menu
item Switch to 2D mode.
One may revert to the
3-D format using the
corresponding Switch to
3D mode context menu
item. Both formats will be
used in this handbook.
NoteThe above screen will appear only if the customization option Resume policy
has been set to Resume les manually. (See customization - described in section
6.1.9)
-
39
4.7 Enter machine dimensions
Machine information and dimensions are entered using the grey data entry keys. The
required missing dimensions are entered directly. Use the navigation keys to highlight
the dimension box and enter dimension by pressing the appropriate data entry keys.
The editing box appears as soon as the rst key is pressed.
Conrm the entered value by pressing either e or . The highlight springs to the next empty dimension box. If necessary, use the navigation keys to highlight the
dimension to be edited.
The dimensions to be entered vary according to machine and type of coupling. In a
standard horizontal alignment application enter dimensions as follows:
Editing box
Horizontal shaft alignment
-
ROTALIGN Ultra iS Shaft handbook
40
4.7.1 Coupling diameter
The coupling diameter can be obtained by measuring the circumference of the
coupling and dividing the value by P (3.142).The default value is 100 mm (10 if set to US units). Should there be need to edit the
value, highlight the value using the navigation keys. Edit the value directly using the
data entry keys. Conrm the new value by pressing either e or . The highlight springs to the next dimension box automatically.
4.7.2 Sensor to coupling center
This is the distance between the distance marking on top of sensALIGN sensor and
the coupling center. Should there be need to edit the value, use the navigation keys
to highlight it, and edit it directly using the data entry keys.
4.7.3 RPM (revolutions per minute)
The default value is 1500 (1800 if set to US units). Should there be need to edit the
value, use the navigation keys to highlight it, and edit it directly using the data entry
keys.
4.7.4 Coupling center to front foot, right machine
This is the distance from the coupling center to the pair of feet on the right machine
nearest to the coupling.
4.7.5 Front foot to back foot, right machine
4.8 Machine properties The set-up screen is used to enter machine dimensions as well as editing machine
properties.
Use h/i to highlight machine to edit.
The distance marking
groove is practical for
attaching a tape measure
lip when determining
required machine train
dimensions.
Distance marking
-
41
Press e to access machine properties. To select machine type, use the navigation keys to highlight the Type box then press e. Select type of machine from the drop down menu that appears using f/g.
Conrm selection by pressing either e or .
The orientation of the machine may be changed using the Toggle and/or Rotate
buttons. Use the navigation buttons to highlight either button, conrming selection
by pressing e. The toggle button is used change the orientation of the selected machine along the shaft axes. The rotate button is used to change the orientation of
the entire machine train from horizontal to vertical orientation and vice versa.
The toggle button ips the
selected train element along
the shaft axes.
The rotate button changes
the entire machine train
orientation (from Horizontal
to Vertical and vice versa).
Horizontal shaft alignment
-
ROTALIGN Ultra iS Shaft handbook
42
To edit machine name, use h/i to place cursor on the Name box then enter the machine name directly using the data entry keys. The editing box appears as soon as
the rst key is pressed.
Conrm entry by pressing either e or .
To enter the type of machine mounting, use the navigation keys to place cursor on
the Fixation box then press e. Select type of mounting from the drop down menu that appears using f/g.
Conrm selection by pressing either e or .
Press and hold down o while observing the status
indicator at the bottom
right corner of the screen.
This displays the character
to be entered.
Repeatedly pressing brings you back to the
set-up screen.
When entering names that
contain both upper and
lower case characters, as
well as numerals, use o to cycle through the three
options.
Note that the navigation
is dependent on the
scheme selected under
Customization. In this
case we are using the
default scheme.
-
43
Depending on the type of mounting, either the position or number needs to be
edited. If the machine is mounted on feet or bearings, the number is edited by placing
cursor using h/i on the xed points box. Press e to highlight the numeral. Edit value using f (increases values) or g (decreases value).
Conrm value by pressing either e or .
If however the machine is ange-mounted, the position
of the ange requires to be entered. To enter ange
location, use the navigation keys to place cursor on the
Location box then press e. Select location from the drop down menu that appears using f/g.
Conrm selection by pressing either e or .
To check or uncheck the
thermal growth enabled
or the stationary machine
box, highlight either box
using the naviagtion key.
Pressing e with the box highlighted, checks or
unchecks the respective
box.
Note that the above
navigation depends on the
scheme selected. In this
particular case the default
scheme is used.
Horizontal shaft alignment
-
ROTALIGN Ultra iS Shaft handbook
44
Thermal growth values can be entered only when the type of mounting is either
machine feet or bearing or V-shaped support, and Thermal growth enabled. To enter
thermal growth values press q while in the Machine type screen. The context menu appears.
Press 2 to access the thermal growth screen. Alternatively, use either f/g to highlight Thermal growth, conrming selection by pressing e.
Use h/i to cycle through the feet positions, highlighting the value boxes. When a value box is highlighted, enter thermal growth value directly using the data entry keys.
Conrm entry by pressing either e or .
Thermal growth values are
activated when the thermal
growth enabled box is
checked.
Thermal growth values may
be entered directly using the
data entry keys.
-
45
4.9 Coupling properties
Coupling properties are entered and edited in the same manner as for machine
properties.
Use the navigation keys to place cursor on the Type or Format box then press e. Select type of coupling or result format from the drop down menu that appears using
f/g.Use the navigation keys to highlight the targets enabled or tolerances enabled
check box. With either box highlighted, press e to check or uncheck the respective box.
Targets and tolerances are activated only when the respective box is checked.
To enter coupling target values, press q while in the Coupling type screen. The context menu appears. Use either f or g to highlight Targets.
Note that the navigation is
dependent on the option
selected in Customization.
The coupling targets
screen may alternatively be
accessed directly from the
context menu by pressing
2.
Horizontal shaft alignment
-
ROTALIGN Ultra iS Shaft handbook
46
Press e to conrm selection. The coupling targets screen that follows appears.
Use the navigation keys to cycle through the coupling properties. To enter coupling
target value, highlight the value box using the navigation keys. With the value box
highlighted, enter target value directly using the data entry keys. Press e or to conrm entry.
With the Type box
highlighted, pressing e reveals a drop down menu
with the available coupling
targets formats. Select
required format using
either f or g , conrming selection by
pressing either e or .
-
47
Pressing q while in Coupling targets screen reveals the context menu shown below.
The displayed menu items perform the following functions:
Clear all values used to clear all entered coupling target values
Sign convention displays the definition and graphic depiction of sign
convention
Left/Right/Both used to select the direction considered when analyzing
coupling targets. If the option Both is selected, coupling target values
cannot be edited
Dial gauge values used to enter coupling target values as dial indicator
readings
Thermal growth used to access the machine thermal growth screen
The context menu to the coupling type screen discussed previously has in addition to
the menu item Targets, also Tolerance and Machine properties.
The displayed context menu
items can be accessed
directly by pressing the
corresponding data entry
key, e.g. pressing 3 opens the sign convention
display.
Press 3 to display the system tolerance
table. Alternatively,
highlight Tolerance using
f/g and conrm selection by pressing e.The menu item Machine
properties is used to access
the machine properties
dialog screen.
Horizontal shaft alignment
-
ROTALIGN Ultra iS Shaft handbook
48
The menu item Tolerance is used to display the system tolerance table.
Pressing q while in Coupling tolerances reveals the context menu shown below.
The displayed menu items perform the following functions:
Tolerances list used to display types of couplings and rpm frequencies
available in the tolerance table
View tolerance displays the coupling tolerance details
Max values used to specify individual tolerances
The displayed tolerance
values are coupling
format, frequency and
rpm dependent. These
parameters may be selected
from the two drop down
menus and the rpm edited
directly.
Note: The item User vector
tolerances is not available
in the standard level.
All the displayed context
menu items can be accessed
directly by pressing the
corresponding data entry
key, e.g. pressing 7 opens the global menu.
-
49
Use the context menu item Max values to access the coupling tolerance screen used
to enter maximum tolerance values.
Use the navigation keys to highlight the Format box. Access the drop down menu by
pressing e. Use f/g to highlight the required format, conrming selection by pressing e or . Using the navigation keys proceed to highlight the respective value box and enter maximum tolerance values with the data entry keys directly.
The values entered above are independent of rpm. When these values are enabled,
they override the system tolerance table.
After machine and coupling properties have been entered, use to return to the set-up screen.
Horizontal shaft alignment
-
ROTALIGN Ultra iS Shaft handbook
50
4.10 Laser beam adjustment
After entering all dimensions, proceed to adjust the laser beam such that it strikes the
sensALIGN sensor lens perpendicular to the lens surface.
1. Slide the sensALIGN laser dust cap to expose the aperture.
sensALIGN laser MUST remain off.
2. With the laser OFF, carry out a preadjustment to ensure that the laser beam will
be emitted perpendicular to the laser housing. Use the two yellow beam position
thumbwheels to centre the bulls-eye as accurately as possible.
3. Press the ON/OFF push button switch to turn sensALIGN laser on.
Do not stare into the laser beam!
4. If both sensALIGN laser and sensor have been positioned at the same height and
roughly the same angular position during mounting (see section 4.5 Mount
sensALIGN laser and sensor ), the laser beam should strike the sensor dust cap.
5. Slide the sensALIGN sensor dust cap to open the sensor lens and observe the
four sensALIGN sensor laser beam adjustment LEDs. If all four LEDs are blinking
green once every second, then the laser beam is correctly centered on the
sensor, and you may proceed with measurement (section 4.11).
6. If however, the laser beam is still not correctly centered, readjust the laser beam
using the yellow vertical and horizontal positioning thumbwheels. Observe the
four laser beam adjustment LEDs while adjusting the thumbwheels.
7. If all four LEDs are blinking green TWICE every second, the angle at which the
laser beam enters the lens is correct, but an offset is present. To eliminate the
offset, slide the sensALIGN sensor dust cap to cover the lens, then (if necessary)
loosen the chain type bracket supporting sensALIGN sensor and move the sensor
sideways. At the same time, if necessary, release the sensALIGN sensor clamping
levers and move the sensor upwards and downwards until the laser beam is
centred on the dust cap.
During this adjustment, DO NOT touch sensALIGN laser.
8. Open the sensor lens by sliding the dust cap and check the blinking of the four
LEDS. If all four are blinking green once every second, then the laser beam has
been correctly centred and measurement may proceed.
WARNING
sensALIGN laser MUST remain off.
bulls-eye
WARNING
Do not stare into the laser beam!
NoteDuring this adjustment, DO NOT touch sensALIGN laser.
-
51
Horizontal shaft alignment
1 2
4
5 6
-
ROTALIGN Ultra iS Shaft handbook
52
4.11 Taking measurements
With all four sensALIGN laser beam adjustment LED blinking green once every
second an indication that the laser beam has been correctly adjusted press m to open the measurement screen. As sensALIGN sensor has not yet been initialized, the
Sensor error message will appear on the screen. Press q then use f/g to highlight the context menu item Sensor selection.
Conrm selection by pressing e. The sensor selection window opens.
Use f/g to highlight Scan for wireless devices, then press e to conrm selection. With this step, the neighbourhood is scanned for Bluetooth devices.
The sensor selection
window may also be used
to select the sensALIGN
sensor and laser cable ALI
4.921-2 to transmit data
between ROTALIGN Ultra iS
computer and sensALIGN
sensor. This emergency
alternative is described in
section 4.11a.
-
53
After the scanning process is completed, any Bluetooth devices detected will be listed
on the screen.
Use f/g to select the appropriate sensALIGN sensor (e.g.sensALIGN 49000134). Press e to conrm selection and proceed with measurement.When sensALIGN sensor is initialized, and the laser beam correctly adjusted, the
measurement screen below appears.
The standard measurement mode is the Continuous Sweep mode. Measurement may
be started automatically when the shafts are rotated or triggered manually using the
e key. The preferred preference may be set under the Measurement options screen which may be accessed via the global menu or the Measurement screen
context menu item Measurement options.
sensALIGN sensors that
have been detected are
stored in the system and
always appear in the sensor
selection screen. Sensors
may be deleted from the
displayed list by pressing
p with the sensor highlighted.
Before proceeding with
rotating shafts, ensure that
the laser dot is inside the
center square.
Horizontal shaft alignment
-
ROTALIGN Ultra iS Shaft handbook
54
Other measurement modes are available. The table below gives a guide as to which
measurement mode is ideal for which measurement. In this section we describe the
Continuous Sweep. Details on the other modes can be found under Measurement
modes in section 5.1.
Measurement mode Application
Continuous Sweep Standard machines
Multipoint measurement Uncoupled shafts, nonrotatable shafts, sleeve
bearings, white metal bearings, journal (radial)
bearings, shafts that are hard to turn, shafts with
herky-jerky rotation, situations with long spans
or severe misalignment that will readily cause the
beam to fall out of range
Static measurement Vertical machines (four feet or ange mounted)
Pass mode Uncoupled shafts, nonrotatable shafts
Dial gauge Verifying measurements taken using dial
indicators
Rotate the shafts a full turn, or as far as possible.
Press e to nish measurement and collect data in order to display results. The following screen appears.
If the intelligent features
are not licenced, the
measurement standard
deviation (SD) will be
displayed if selected
under the measurement
screen context menu item
Measurement options.
Measurement quality is an
intelligent feature based on
several measurement and
environmental criteria. The
resulting quality is depicted
using the following colour
codes:
excellent
good
acceptable
poor
-
55
Alternatively, the coupling results may be displayed after shaft rotation by pressing
q and highlighting the menu item Stop from the context menu that appears.
The hint appears only if
the customization option
Workow is enabled.
The option is selected
via Conguration-
>Customization.
Highlighting Yes using
f/g and conrming selection by
pressing e, displays feet and coupling results.
Note that the coupling
values presently displayed
are real-time values.
Horizontal shaft alignment
-
ROTALIGN Ultra iS Shaft handbook
56
4.11a Taking measurements using the sensALIGN sensor
and laser cable
If necessary, measurement data from sensALIGN sensor may be transferred to
ROTALIGN Ultra iS computer using the sensALIGN sensor and laser cable ALI 4.921-2.
Such cases may arise due to low sensor battery capacity or when measurement is
carried out with the sensor rechargeable battery dismounted.
1. Insert the quick t straight-ended sensALIGN sensor and laser cable plug into the
eight-pin sensor socket on the top of ROTALIGN Ultra iS computer housing with
the red dot at the front.
Match the double-sided arrow head on the plug to the red marking on the
socket to ensure proper plug orientation; otherwise the pins inside the plug may
be damaged.
To disconnect, grasp the ribbed collar of the plug on the sensALIGN sensor
and laser cable (ALI 4.921-2) and carefully pull it out of the ROTALIGN Ultra iS
computer sensor socket.
2. Insert the right-angle connector on the sensALIGN sensor and laser cable ALI
4.921-2 into the sensALIGN sensor charger/adapter/cable socket.
Insert the connector such that the red dot on the connector matches the red
marking on the sensALIGN sensor socket to ensure proper plug orientation;
otherwise the pins inside the connector may be damaged.
To disconnect, grasp the ribbed collar of the right-angled connector and carefully
pull it out of the sensALIGN sensor charger/adapter/cable socket.
Note that sensALIGN laser
may also be powered
through the ROTALIGN
Ultra iS computer using
the sensor/laser cable
ALI 4.921-2. Connection
between ROTALIGN Ultra
iS computer and laser
is similar to the sensor
connection described on
the main column.
CAUTION
Match the double-sided arrow head on the plug to the red marking on the
socket to ensure proper plug orientation; otherwise the pins inside the plug may
be damaged.
To disconnect, grasp the ribbed collar of the plug on the sensALIGN sensor
and laser cable (ALI 4.921-2) and carefully pull it out of the ROTALIGN Ultra iS
computer sensor socket.
CAUTION
Insert the connector such that the red dot on the connector matches the red
marking on the sensALIGN sensor socket to ensure proper plug orientation;
otherwise the pins inside the connector may be damaged.
To disconnect, grasp the ribbed collar of the right-angled connector and carefully
pull it out of the sensALIGN sensor charger/adapter/cable socket.If sensALIGN sensor
rechargeable battery
capacity is low, connecting
the sensALIGN charger/
adapter during
measurement cuts off
the sensor measurement
mode. Measurement
may be resumed only by
pressing the sensor On/
Off push button briey.
Refer to the appendix for
the sensor/laser on/off/
charge workow.
OPEN
sensALIGN sensor and
laser cable ALI 4.921-2
sensALIGN sensor socket
ROTALIGN Ultra iS
computer sensor socket
-
57
3. Use the Measurement screen context menu item Sensor selection to set
the mode in which measurement data is transferred from sensALIGN sensor to
ROTALIGN Ultra iS computer.
4. Use f/g to highlight sensALIGN cable 1 then press e to conrm selection. sensALIGN sensor will be initialized and measurement using the
sensALIGN sensor and laser cable ALI 4.921-2 may proceed.
4.12 Results Once measurement is completed, press RES to view alignment results. ROTALIGN
Ultra iS intelligent features guide the user to obtain reliable alignment results.
The above display shows the measured alignment condition along with numerical
values for the actual machine feet positions.
With ROTALIGN Ultra iS, any one pair of feet can be designated as static.
In this example, the left
machine was dened during
set-up as static.
NoteWith ROTALIGN Ultra iS, any one pair of feet can be designated as static.
Horizontal shaft alignment
Coupling values
Feet position
-
ROTALIGN Ultra iS Shaft handbook
58
The context menu shown below appears when q is pressed while in results screen.
The context menu items are scrolled using f/g. Item selection is conrmed by pressing e. Alternatively, access the numbered menu items directly by pressing the corresponding data entry key.
To designate any pair of
feet xed, place the yellow
vertical cursor line on the
feet pair using h/i. Press e to x the selected pair of feet. The feet position is
highlighted black. To unx
any pair of feet, place the
cursor line on the static pair
of feet pair using h/i, then press e.
Note that certain context
menu items contain
sub-menu items that are
accessed using h. These include: Save, View,
Scale and More....
Unxed feet pair Static feet pair
-
59
The Results options screen below is accessed via the context menu item More...
followed by the sub-menu item Options.
The viewing option can be set to show just the measured alignment values without
regard to any target values or thermal growth values that have been entered, even if
they are active. Select Actual view for this option. Alternatively, you may also select
Specication view which shows just the effect of any target specications and/or
thermal growth values that may have been entered and activated, without regard to
any measured misalignment. The default view, and the option that should be used
when actually performing alignment corrections is Actual Specication.
If the option Show correction arrows is activated, coloured tolerance arrows appear
at the feet positions as further help in determining the coupling alignment condition.
Note that these three
options are related to the
scaling of the machine
graphics. Only one of
the two options ( Show
machine icons or Show
reference line) can be
selected at any one time.
When machine icons are
selected, the options
Show orientation text
and Show reference line
are greyed out.
Tolerance envelopes can
be activated or deactivated
from the drop down menu
in this screen.
The colour codes are
translated with respect to
the coupling alignment
condition as follows:
Blue excellent [foot should
not be moved]
Green good [if possible
foot should remain
unaltered]
Red poor [foot requires
moving to attain a better
alignment condition]
Horizontal shaft alignment
-
ROTALIGN Ultra iS Shaft handbook
60
Further scaling options are provided by the context menu item Scale whose
sub-menu items include Original refers to scaling to size, Equal machine length
both stationary and moveable machines are displayed with equal size, Equal xation
distance graphic is displayed with equal separation between the machine forward
and back feet, All equal displays the graphic with identical sizes for both machine
and feet positions.
The context menu is also used to select the desired depiction.
-
61
4.12.1 Sign convention
The following sign convention is used in the evaluation of alignment results.
With left machine stationary, gap is positive when open at top or side away from
viewer. The viewer is considered to be standing in front of the machines as they
appear on the display.
Both vertical and horizontal results show the foot position relative to the stationary
machine centerline. Positive values indicate that machine is upwards or away from
viewer. Negative values indicate that machine is downwards or towards the viewer.
4.12.2 Alignment quality
The smiley symbol by the coupling results indicates the degree to which the measured
alignment condition meets tolerances. The smiley face appears only when tolerances
have been enabled (see section 4.9).
If all results lie within tolerance, no alignment corrections are necessary.
The different views may
also be cycled by pressing
g.In this example following
results options have been
selected:
Show both left and right
envelopes, Show machine
icons, Show correction
arrows
Excellent
Acceptable
Out of tolerance
NoteIf all results lie within tolerance, no alignment corrections are necessary.
Horizontal shaft alignment
-
ROTALIGN Ultra iS Shaft handbook
62
4.13 Align machine
To align your machine you need to move it vertically by shimming the feet, and
horizontally by shifting it sideways. You can perform these operations in either order
or simultaneously.
4.13.1 Shim first
It is recommended to perform vertical corrections rst, since the horizontal
condition is easily affected by the process of loosening anchor bolts and inserting/
removing shims, whereas the vertical condition is less prone to being affected
when performing horizontal moves. You may need to recheck soft foot before
proceeding.
4.13.2a Move simulator
As the name suggests, the Move simulator is used to simulate shim values and
horizontal movement corrections that are required to correct the alignment condition.
The simulator takes into account the shim thickness available and the amount by
which the machines can be physically moved.
4.13.2b Initiating the Move simulator
Press q while in the results screen. The context menu appears. Use f/g to highlight the context menu item Move simulator.
Conrm selection by pressing e. The Move simulator screen opens. To effectively use the Move simulator, it is necessary to set the required machine movement step.
This value is set using the Move simulator screen context menu Move step. Call up
the context menu by pressing q while in the Move simulator screen.
NoteIt is recommended to perform vertical corrections rst, since the horizontal
condition is easily affected by the process of loosening anchor bolts and inserting/
removing shims, whereas the vertical condition is less prone to being affected
when performing horizontal moves. You may need to recheck soft foot before
proceeding.
-
63
Use f/g to highlight the context menu item Move step then press e to conrm selection. The screen below with the editing box appears.
Use the data entry keys to entire the desired movement step value, conrming entry
by pressing e or .
The activated tolerance
envelopes are an
assistance to determining
the alignment condition
of machines.
Horizontal shaft alignment
-
ROTALIGN Ultra iS Shaft handbook
64
Use i/h to place the cursor on the feet pair requiring simulation. With the cursor on the selected feet pair, use f/g to simulate the movement in accordance with the set step value. Pressing f moves the machine upwards (in vertical view) or away from viewer (in horizontal view) by the movement value factor. Pressing g moves the machine downwards (in vertical view) or towards viewer (in horizontal
view) by the movement value factor.
Test shimming/movement values may be entered directly by highlighting feet pair to
be shimmed/moved then conrming selection by pressing e. The test values are entered in the editing box that appears.
The Move simulator context menu contains items that are helpful in analysing a
simulation. These include the menu item Reset values and the submenu item Details
[ More... -> Details]. Selecting Reset values and conrming selection resets the
simulator to the original result values. Selecting Details and conrming selection
reveals the feet corrections to zero alignment, as well as any entered thermal growth
values.
In this example, an excellent
alignment condition has
been achieved by sinking
the front feet 0.30 mm (2x
the movement step value)
and the back feet 0.50 mm.
(5x the movement step
value
-
65
The Simulator options screen may be accessed via the Move simulator screen context
menu item More.... Select More... -> Options then press e to conrm selection. The Simulator options screen opens.
While in Simulator options screen, use the navigation keys to highlight the
movement step value. With the value highlighted, use the data entry keys to edit this
value. The editing box appears as soon as any data entry key is pressed. After editing
the movement value, press e or to conrm entry. Press to return to the Move simulator screen.
The correction values
displayed from the submenu
item Details match those
obtained using the Move
simulator.
The Simulator options
screen may also be used
to edit the movement step
value, activate the tolerance
envelopes, set the results
format and display machine
icons in the background.
Horizontal shaft alignment
-
ROTALIGN Ultra iS Shaft handbook
66
4.13.3 Horizontal and vertical live MOVE
The alignment corrections involving shimming and the lateral positioning of the
machines can be followed in a real-time interactive display. From the results screen,
press q. The context menu appears. Use f/g to highlight Move.
Press e to conrm selection and start live Move.
If the laser beam is centered proceed to carry out live horizontal and vertical Move.
If however the laser beam is not centered, use the Move measurement screen
context menu item XY view (see section 5.2.7) to center the laser beam then
press to go back to the results screen to proceed with live Move.
Live horizontal and vertical
Move can be monitored
simultaneously. Move is
carried out in one direction
(say vertical shimming rst)
then in the other direction
(say horizontal Move).
NoteIf however the laser beam is not centered, use the Move measurement screen
context menu item XY view (see section 5.2.7) to center the laser beam then
press to go back to the results screen to proceed with live Move.
-
67
Live Move may be stopped via the Move measurement screen context menu item
Stop. Use f/g to highlight the menu item Stop then conrm selection by pressing e.
If the results view is zoomed to the vertical view when the Move function is
started, only the vertical condition will be monitored. Likewise, if the results view
is zoomed to the horizontal view when the Move function is started, only the
horizontal condition will be monitored. If the view is set to both vertical and
horizontal (as illustrated above) then both conditions will be monitored simulta-
neously. This information is recorded in the measurement table.
4.13.4 Shimming
i) Prepare the machines for shimming by ensuring the following:
The foot bolts are clean, intact and removable
Soft foot has been eliminated
The feet have enough shims under them should lowering the machine be
necessary.
Good quality shims such as PERMABLOC, MYLAR or LAMIBLOC are available
from PRFTECHNIK Alignment Systems
ii) Loosen foot bolts while avoiding to move the machine horizontally. If any foot
comes off the ground when loosened, suspect soft foot.
iii) Use the vertical foot correction values to shim BOTH front and back feet as
required. Positive feet values indicate that the feet are high and therefore shims
should be removed, while negative feet values indicate that the feet are low and
suggest addition of shim thickness.
Note that the Move
measurement screen
context menu item
Averaging may be used to
set the number of readings
to be averaged.
The context menu item
Extend may be used
to broaden the laser
beam detection range
measurement range.
The features Extend and
Averaging are described
in sections 5.2.6 and 5.2.9
r